INTRODUCTION

The UOP Oleflex process is a catalytic dehydrogenation

technology for the production of light olefins from their
corresponding paraffins. One specific application of this
technology produces propylene from propane. Propylene
is the words second largest petrochemical commodity
and is used in the production of polypropylene, acry-
lonitrile, acrylic acid, acrolein, propylene oxide and
glycols, plasticizer oxo alcohols, cumene, isopropyl
alcohol, and acetone. The growth in propylene production
is primarily driven by the industry demand for
polypropylene, which is used in such everyday prod-
ucts as packaging materials and outdoor clothing. The
growth rate of polypropylene is expected to be 5% per
year for the near future. The Oleflex process provides:
A dedicated source of propylene supply for
downstream use.
Increased control over long-term propylene costs.
High-quality propylene production, which leads
to high-quality polymers.
Potential for process integration with downstream
technology.
Continuous on-stream production of propylene.
In addition, the Oleflex process utilizes UOPs propri-
etary equipment and systems for optimal operations,
including PSA Polybed
TM
units, modular CCR, UOP
lock hopper control, MD
TM
distillation trays, High-Flux
TM
tubes, and process instrumentation controls (PIC).
Integration of these products within the Oleflex process
results in significant capital and operating cost savings
for the complex and provides an overall guarantee for
the Oleflex process and products. With the use of CCR
catalyst regeneration, the processing unit does not have
to be shut down to change out the catalyst.
APPLICATIONS
The majority of propylene is produced as a byproduct of
petroleum refineries (FCC/RCC) and olefin plant steam
crackers. As a result, most propylene is a byproduct of
other products, specifically gasoline and ethylene.
However, when production capacity is not coupled with
a demand for those byproducts, a supply/demand
imbalance can occur. The Oleflex process provides
petrochemical producers with a catalytic, on-purpose
means of making propylene independent of the demand
for gasoline and ethylene.
The Oleflex process provides producers with a high-
quality propylene,
which then leads
to high-quality
polymers. This
process consumes
less polymeriza-
tion catalyst
because of fewer
impurities in the
propylene product
and has the poten-
tial to be integrated
with existing
downstream tech-
nology.
DESCRIPTION
The UOP Oleflex process is separated into three different
sections: the reactor section, the product recovery section,
and the catalyst regeneration section.
The reactor section of the Oleflex process consists of
four radial-flow reactors, charge and interstage heaters,
and a reactor feed-effluent heat exchanger. In the product
recovery section, the reactor effluent is cooled, com-
pressed, dried, and sent to a cryogenic system to sepa-
Oleflex
TM
Process for Propylene Production
rate hydrogen from hydrocarbon. The net gas is recov-
ered at 85 to 93 mol-% hydrogen purity. Separator liq-
uid is sent to a selective hydrogenation unit to eliminate
diolefins and acetylenes. Then the liq-
uid goes to a deethanizer and propane-
propylene (P-P) splitter to produce a
chemical or polymer-grade propylene
product. Unconverted propane is recy-
cled to the reactor section.
The selective diolefin and acetylene
hydrogenation step is accomplished
with the Hls SHP process licensed
by UOP. The catalyst regeneration sec-
tion burns coke off the catalyst and
returns it to fresh activity.
FEEDSTOCK
The feedstock to a C
3
Oleflex process
unit is propane. Propane is recovered
from propane-rich LPG streams from
gas plants. Propane is also available in smaller quanti-
ties as a byproduct from such refinery operations as
hydrocracking, fluidized catalytic cracking (FCC) and
(RCC)* resid catalytic cracking units.
CATALYST
The Olexflex process uses a platinum catalyst to promote
the dehydrogenation reaction. The DeH-14 catalyst,
introducted in 2001, represents the fifth generation of
catalyst. Not only does the DeH-14 maintain the high
activity and selectivity and low attrition rates required
for the dehydrogenation process, it also has lower plat-
inum investment than earlier catalysts.
COMMERCIAL EXPERIENCE
The Oleflex process was first commercialized in 1990.
Currently five propane units and one mixed
propane/isobutane unit produce more than 1,250,000
MTA of propylene. In addition there are five isobutane
units that have been commissioned.
FOR MORE INFORMATION
Oleflex technological services are available on request.
For more information, contact your local UOP
representative or contact our Des Plaines sales office:
e-mail: info@uop.com
fax: +1-847-391-2253
phone: +1-847-391-2000
UOP 4217-25 0104PTE0Cr
Oleflex SHP
Propane
Feed
Net Gas H
2
C
2
-
Propylene
C
4
+
Depropanizer
Deethanizer
P-P Splitter
Reactor Section CCR Section
Heaters
Fresh and
Recycle Feed
Net Separator
Offgas
To Propylene
Recovery
Turbo
Expander
Rx Effluent
Compressor
Dryer
H
2
Recycle
C
C
R
Product Separation Section
C
3
Oleflex Complex
C
3
Oleflex Process
* Service mark of Ashland Oil
2004 UOP LLC. All rights reserved.
The information in this document should not be construed as a representation for
which UOP assumes legal responsibility, or an authorization or recommendation to
practice a patented invention without a license.
UOP LLC
25 East Algonquin Road
Des Plaines, IL 60017-5017, U.S.A.
www.uop.com